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This paper was presented at the 10th Offshore Mediterranean Conference and Exhibition in Ravenna, Italy, March 23-25, 2011.
It was selected for presentation by OMC 2011 Programme Committee following review of information contained in the abstract
submitted by the author(s). The Paper as presented at OMC 2011 has not been reviewed by the Programme Committee.
ABSTRACT
Casing while Drilling (CwD) is a new technology that has proved its efficiency in more than
40 locations all over the world.
This technology allows drilling and casing the well simultaneously, saving time and money.
To date, more than 3000 sections were successfully drilled using CwD system. CwD system
uses conventional rig with little modifications or a special PLC rig.
Moreover, CwD improves personnel safety, which is an absolutely important side, by
reducing pipe handling, which causes about 70% of incidents. It minimizes connection time
by 25%, which affects the total time by reduction. Its use saves money, about 30% for
troublesome wells and 15% for trouble free wells. It also improves wellbore stability,
eliminates problems related to tripping of string, reduces lost of circulation, and has some
environmental impacts.
CwD hasnt been used in Egypt, yet. But it can be, efficiently, used especially in drilling
offshore wells in The Nile Delta, where drilling costs are very high, especially in deepwater
wells in The Mediterranean which may cost $100,000,000 and in Nile delta about
$25,000,000. As a result, financial saving will be significant.
This paper is studying the implementation of this new innovative technology in the Nile Delta
by showing the lithology, and discussing the problems encountered, then comparing the
results of the previous case histories in other countries with the problems encountered during
drilling offshore wells in Nile and how CwD can save significant time and cost. Also the paper
shows expected results for a mud hydraulics programs for each section to be drilled by CwD.
INTRODUCTION
We dont trip. We drill it; the casing is there. Boyle describes, the vice president of CASING
DRILLINGTM, for Tesco Corporation.1
This technology is the latest innovated one in drilling oil and gas wells. Casing while Drilling
proved that it is a technology of potential use in drilling, both onshore and offshore oil and
gas wells; even they are vertical, directional, or horizontal. It allows the operators to drill and
case the well simultaneously. Moreover, it is the solution for many drilling problems
encountered during drilling oil and gas wells. Until the end of August 2009, TESCO Corp.
had drilled about 3,100,000 ft in 1130 sections.2 Weatherford also uses Drilling With
CasingTM technology on more than 800 projects in almost 1,000 intervals including more than
350 complete wells.1 It has gained its strength from the great advancing in metallurgy which
allows the casing to sustain greater strength to carry higher torque.
In the past, 9 inches casing can handle only 14,000 ft-lb. But now, special 9 inches
casing it can take more than 100,000 ft-lb.1 TESCO and Weatherford are the two main
providers of this technology. They offer different approaches to help drillers get the bit to total
depth.1
It used successfully in more than 40 locations all over the world. These locations include
United States of America, Canada, Gulf of Mexico, Ecuador, Brazil, Argentina, United
Kingdom, China, Indonesia, Norway, and Columbia. It also used in the Middle East in United
Arab of Emeritus, Qatar, and Sultanate of Oman.3,4,5
1
DWC allows operators to drill in troublesome formations where loss of circulation and
wellbore instability is often happened during conventional drilling. It also can reduce wellconstruction costs, improve operational efficiency and safety, and minimize environmental
impact. It improves personnel safety by reducing pipe handling which causes about 70% of
incidents. Casing strings have longer joints than standard drillpipes, which means that drillers
make about 25% fewer connections.6 for offshore wells; it reduces drilling costs due to the
high cost of rigs per day.7
CwD PROCEDURES
Casing While Drilling system integrates the drilling and casing running processes into a
single operation, providing more efficient way to drill a well. The drilling with the casing
system may be provided by a conventional top drive rig or a special automated PLC
controlled rig for drilling the well. After the rig is set at the wellsite, a normal casing is
prepared by adding the torque rings, the casing joints are connected by using the casing
drive system (CDS). A non-retrievable drilling bit is attached to the end of the casing; this
drilling bit may be drillable. The bottom Hole Assembly (BHA) may be attached to the casing
string. This BHA consists of pilot bit, this bit drill a pilot hole which needs to be opened, so an
under reamer is used to open the hole. In directional drilling, MWD, LWD and motors are
also added to the BHA. The BHA is attached to Drill Lock Assembly (DLA) which connects
the BHA to a profile nipple immediately above casing shoe. After drilling the desired section,
the BHA has been retrieved and cementing takes place, and then a new section is drilled by
the same way.
There are two primary CwD techniques available in the market: one technique allows the
BHA to be changed without tripping the casing, and the other one uses a fixed cutter pilot bit.
The system is composed of down hole and surface components that provide the ability to
use normal oil field casing as the drill string. The casing connections require a change from
the conventional well design because they must provide adequate torsional strength, fatigue
resistance. The casing provides hydraulic and mechanical energy to a retrievable drilling
assembly suspended from a profile nipple located near the bottom of the casing.
The BHA is attached to a Drill Lock Assembly (DLA) which connects the BHA to a profile
nipple immediately above the casing shoe. The BHA can be tripped with wire line, coiled
tubing or drill pipe. A large wire line unit with sufficient power to run and pull the BHA
efficiently is needed.
A wire line retrievable drilling assembly is suspended in a profile nipple located near the
bottom of the casing. The drilling fluid is circulated down the casing inner diameter and back
through the annulus between the casing and wellbore.
The drilling assembly below the DLA terminates in a pilot bit, but it may include other
conventional drill-string components such as an underreamer, mud motor, coring or
directional assembly. For vertical wells, the BHA may consist of a pilot bit, stabilizers, and
underreamer. For directional wells, the BHA would include a down hole motor and MWD and
LWD.
In most Casing While Drilling applications, an underreamer is used above the pilot bit to open
the hole from the pilot bit diameter to the final diameter. The pilot bit must be sized to pass
through the active casing and the underreamer opens the hole to the size that would
normally be drilled to run the active casing. For example, an 8 pilot bit and 12
underreamer may be used while drilling with 9 36 lb/ft casing.
Each joint of casing is picked up with a Casing Drive System located below the top drive.
This tool supports the full weight of the casing string, applies torque for both drilling and
make-up, and facilitates circulation without making a threaded connection to the top of the
casing.8
For offshore applications, most Drilling with casing-about 80% is done by attaching a nonretrievable bit to the bottom of the casing and leaving the bit in the hole.7 Nowadays, a
retrievable system is used mostly in drilling offshore wells
Directional casing while drilling (DCwD) uses a steerable BHA that is retrievednot left in
the hole, and makes DCwD a viable alternative to conventional directional drilling in depleted
or mature fields that have severe lost circulation and wellbore stability problems.7
2
El Wastiani Formation consists of thick quartzose sands with argillaceous interbeds. Finally,
Mit Ghamr Formation is a typical fill-up of a basin with shaley sands, coquina beds, clays and
peat. Its age is Uppermost Pliocene to Quaternary. As El Wastani Formation and Mit Ghamr
Formation are formed from unconsolidated sand, so losses may occur in those formations,
Also, El Wastani formation contains some clay which may cause bit balling. Table 1 gives a
summary for the formations, the average depth of each in feet, and the expected drilling
problem during drilling those formations.
Tab. 1: Summary for formations, depths and expected problems
Formation Name
Pleistocene
Upper Pliocene
Wastani
Kafr El Sheikh
Abu Madi
Seabed 1850
1850 2850
2850 6230
6230 11345
11345 12303
PRESSURE EVALUATION
Figure 2, shows the pressure gradient curves for the Nile Delta (the depth is in meter and the
mud weight in gm/cc). The fracture gradient has been estimated from the LOT/FIT data from
the wells drilled in the area. At the 9 casing shoes in the reference wells mainly FIT were
recorded, and in any case the values of the LOT around 15 ppg (1.80 sg) were enough to
drill the 8 section with a mud weight of about 10.66 ppg (1.28 sg).
The overburden gradient has been estimated from the available data for the Nile delta area,
corrected for 250 ft (75 m) of water depth.
It is obvious that form 8860 ft to above the producing zone, the pore pressure gradient
decreased, this is due to compaction of the shale.
From the study of the pore pressure and fracture pressure gradient in Nile Delta, it is
recommended to drill five section which will be discussed in the next section.
Drilling Phase
CSG Size
Formation
26 x 36
16" x 26
16"
12
8
600
4130
8530
11810
12000
30
18
13
9
7
Mit Ghamr
Mit Ghamr Wastani
Wastani - Kafr El Sheikh
Kafr El Sheikh Abu Madi
Abu Madi Reservoir
16" section for 13 casing, 16" section will be drilled throughout the bottom part of the
Wastani formation and the Kafr El Sheikh formation. This phase is drilled to 10,740 ftVD
(3,274 mVD) RKB. KOP for the section in object is at 4,365 ftMD (1,300m MD,) and planned
EOB is at 5,775 ftMD (1,760m MD); with final inclination 53.65 (DLS = 2/100 ft).
12 section for 9 casing, The lithology throughout this section consists mainly of shale
with interbedded sandstone streaks of the Kafr El Sheikh and Abu Madi formations.. This phase
is drilled to 15,920 ftVD (4,853 mVD) RKB. KOP at 10,825 ftMD (3,300mMD) to reach final
inclination of 53.5, then at 14,750 ftMD (4,497 mMD) drop angle till it reach 35 at 15,666
ftMD (4,775 mMD).
8 section for 7 casing, This phase will be drilled through the Abu Madi formation and
cross the well reservoir. The litho logy of this interval consists mainly of sandstone, claystone &
shale. This phase is drilled to 16,227 ftVD (4,946 mVD) RKB.
For drilling using CwD technique, we can make use of the easy of being retrieving the BHA
and cementing the entire casing. The proposed design for the CwD in the area (shown in
figure 3b) is to drilled only four sections, by merging the 16" section and 12 section in one
section of 16 hole and drilling will be with the same mud weight as casing while drilling can
6
use higher mud weight, but less than the fracture pressure, without being worried form loss
of circulation or from fracturing the formation this is due to smear effect which will be
discussed later. In case of any emerging situation, the BHA will be retrieved in less than two
hours and then casing the entire casing to the desired cement level in annulus. Moreover,
CwD gives the chance to drill the reservoir with the above section so, eliminating the sections
to three, this gives the advantage of reducing the number of casing strings and to reduce the
casing joints used so decreasing the time by reducing tripping for each section and WOC for
the two sections. Reducing cost achieved by reducing the number of joints used, and
decreases NPT.
MUD PROGRAM
For drilling the upper holes, we use WBM as we drill through mainly sand formation, but as
we go deeper, OBM replaces WBM due to presence of time dependent shale so avoid the
swell of the shaley formations. Table 2 shows the sections drilled with the formations
encountered and the mud type and weight.
Tab. 3: Mud Program Summary
Drilling Phase
Mud Type
Formation
26 x 36
16" x 26
16"
12
8
Spud Mud
WBM
OBM
OBM
DIF
Sea water
8.83 9.83
11.5 12
11.5 12
9.58 - 10
Mit Ghamr
Mit Ghamr Wastani
Wastani - Kafr El Sheikh
Kafr El Sheikh Abu Madi
Abu Madi Reservoir
26x36 section, the section will be drilled without return at surface with seawater and super
sweep pills for hole cleaning purposes.
16x26 section, the mud (WBM inhibited) weight should range between 8.83 ppg to 9.83
ppg (1.10 sg to 1.18 sg). The mud system will be treated from the beginning with KCl to
enhance the inhibition properties and properly face the gumbo shale of the Mit Ghamr /
Wastani formation. The high fluid loss inherent to the system will ensure the deposition of an
7
adequate filter cake across loose surface sands thereby minimizing their sloughing into the
wellbore.
16" section, Oil Base Mud will be used to drill this section. The mud weight should range
from 11.5 ppg up to 12 ppg (1.40 sg up to 1.45 sg). Mud Density should be closely
maintained to avoid any excessive mud weight as this can cause borehole instability
problems. The hydrostatic pressure exerted by the column of fluid can cause an increase in
near wellbore pore pressure, which may in turn cause a failure of formation integrity. OBM
used to minimize ECDs by controlling the amount of Low Gravity Solids (LGS) build-up in the fluid
and by optimizing flow rates. Moreover, provide inhibition of hydrateable shale, prevent bit/BHA
balling, hydration and swelling of cuttings, and provide good borehole stability. Finally effectively
seal porous zones, minimize fluid loss to the formation and provide a good filter cake.
12 section for 9 casing, Mud Density should be closely maintained to avoid any
excessive mud weight as this can cause borehole instability problems. The hydrostatic pressure
exerted by the column of fluid can cause an increase in near wellbore pore pressure, which may
in turn cause a failure of formation integrity.
8 section for 7 casing, Extreme care should be taken while drilling this interval due to the
smaller hole size, depth and the types of formation exposed. A minimum mud weight is required
to avoid any differential pressure sticking and tight control on fluid loss will also be required. A
good quality filter cake is essential in order to minimize any pay zone formation damage and
avoid any differential pressure sticking. Loss of circulation can be expected and conventional
LCM is not recommended in order to avoid any formation damage through this reservoir zone,
however acid soluble plugging material is recommended if cutting the mud weight does not solve
the problem.
CwD can be used efficiently in this case in Nile Delta as wellbore stability is a critical issue
due to the presence of the smear effect which achieved better wellbore stability in all
previous wells drills all over the world. Moreover, loss of circulation can be eliminated or even
prevented by the same effect, which will reduce the cost of using loss of circulation materials
or other chemicals which used to treat the loss of circulation. A case study in South Texas
will be discussed after this section shows that CwD reduce loss of circulation dramatically
and improve wellbore stability and can be used in drilling depleted zones with higher mud
weight.
$200,000, compared to re-drilling the well conventionally, assuming that a second attempt
would have been successful. Figure 5 shows a comparison between the two wells.
Clearly there is substantial evidence that the Casing While Drilling process can be used to
drill through weak depleted zones without the massive lost circulation that so frequently
occurs when drilling with drillpipe and collars. The exact mechanism that provides this benefit
is not proven yet, but it is believed to be the result of mechanically working drilled solids into
the face of the borehole to reduce permeability and plug small fractures that are created
while drilling. The cuttings recovered from Casing Drilled wells are usually smaller than those
recovered from conventionally drilled wells. Since the size of the PDC cutters and the ROP in
both cases are similar, the cause of the reduced cutting size is assumed to be due to
regrinding the cuttings between the casing and borehole wall.9
SMEAR EFFECT
Drilling with casing had proven to reduce lost of circulation, this is due to the phenomenon
that has been designated as the smear or plastering effect. It creates a super touch filter
super impermeable filter cake. Filter cake is smeared into the wall and is not scraped off by
bit passage or tool joint impacts, cuttings are ground up more finely, this also improves the
stability of the wellbore, further strengthening the wellbore which offers the additional benefit
of improved well control and stability. Although several explanations have been put forward,
the most logical one is based on a combination of Casing While Drilling attributes such as:
Smoother rotation of the casing against the well bore wall (i.e., unlike wall banging
caused by drill pipe rotating within a larger annulus).
Thicker filter cake opposite porous and permeable zones (i.e., not as much emphasis
needs to be placed on minimizing the drilling mud water loss).
A much smaller annulus between each combination of casing O.D. and hole size.
This probable combination of circumstances creates some type of plastering, packing and/or
troweling effect against and into the formation(s) along the well bore as the casing is being
rotated. As a result, the smear/plastering effect enhances the strength of a formation along
the well bore wall to eliminate or minimize loss of circulation into the weak formations while
reducing the potential influx of formation fluids into the annulus (i.e., gas or water flows).
This phenomenon has been observed many times, but is not well understood, as many wells
were drilled in sever lost of circulation area without significant loss in circulation. The
following paragraphs describe some of the evidence supporting the observation that the
Casing While Drilling process results in improved wellbore integrity.10
MUD HYDRAULIC
Hydraulics plays an important role during drilling. By optimizing mud hydraulics, we can
achieve better hole cleaning, and maximize penetration rate by using an optimum flow rate
and pressure drop across bit.
During drilling with casing mud hydraulics is very critical issue due to small annular clearance
which may cause turbulent flow as this small clearance increase the actual velocity and may
decrease the difference between the critical and actual velocities. The slip velocity should
also be taken into account so as to be less than the actual velocity to ensure that mud can lift
the cuttings out of wellbore.
To ensure better hole cleaning, flow rate should be selected to optimize the impact factor on
the bit. Optimizing for Hydraulic horse power is taken in account to increase the ROP.
The optimum flow rate that used is the flow rate which achieves:
1- Actual velocity in annulus more than slip velocity.
2- Keep flow laminar in annulus.
3- Increase ROP by achieving perfect cleaning.
Some calculations were done on the different sections proposed to be drilled by CwD
technique and the results are shown in Table 4 for the critical section, which is the longest
one, of length 15,820 ftMD (4820 mMD).
During calculation the flow rate the following points were taken in account:
1. For calculating different parameters during designing the hydraulics program, same
mud weight, viscosimeter readings, cuttings density, and hole inclination.
2. For calculating the slip velocity, smaller cutting diameter was assumed as it was
observed form the previous case study. The slip velocity calculated for hole
inclination of 53.65 and 36 degrees, using Hopkin Slip Velocity chart.11 Slip velocity
was calculated to be 1.28 ft/s.
3. Pressure drops in the different elements are calculated using power law model.
4. For optimization for the impact factor, and for bit hydraulic horse power, the ratio
between total pump pressure to the fluid looses across the bit taken to be 0.5 and .65
respectively.12
5. For obtaining good hole cleaning a rule of thumb stated that the flow rate should be
range from 30 to 50 gallon be minute for each inch of hole size.
6. Rock bit is used with three nozzles.
7. Pump pressure with flow rate 2250 psi.
8. Mud weight of 11.5 ppg used as it is suitable to drill through the pay zone if needed.
Tab. 4: Mud Hydraulics Summary for 26 hole
Technique
Annular
Velocity (ft/s)
Critical Velocity
(ft/s)
Flow Rate
(gal/min)
EMW (ppg)
Nozzle
Size
Conventional
4.067
2.54
7.14
800 (actual)
12.16
3X18
7.14
7.14
12.07
12.28
2X12/14
15/2X16
CwD
4.4
NPT
(Days)
Using CwD
PT (Days)
4.81
NPT (Days)
Site Preparation
604
3.5
1.25
3.5
0.38
4190
4.5
12.44
4.5
3.52
10795
8.39
9.62
14.94
15.2
15950
6.55
16.63
16190
16190
1.01
10.26
1.01
23.99
55.01
23.99
5
28.91
4.81
4- The labor and the accidents that may happen to them during pipe connection, by
using CDS.
5- Reduction in using cement as more than one section will be drilled together.
CONCLUSION
Using CwD in Nile Delta area is an effective tool which can be used in drilling offshore wells.
From the study introduced in this paper, it is concluded that by using CwD in Nile delta, we
can get the following benefits:
1- Reach the total depth safely.
2- Achieve better hole cleaning.
3- Reduce loss of circulation in permeable formation and formation of super
impermeable filter cake.
4- Improve wellbore stability.
5- Time saving is achieved, about 33% from NPT.
6- Cost savings are significant, about 15% of total cost based on rig rate.
RECOMMENDATIONS
I recommend using this promising technology in Egypt, as it will save time, cost, and achieve
better wellbore stability. Moreover, for deep wells in deep water in Mediterranean we can use
a specialized CwD which do not need any workers on the rig except few as it is an
automated rig, this rig reduces dramatically the accidents that happen to people on the rig,
and increase personnel safety.
ACKNOWLEDGEMENT
Id like to thank the engineers who helped me in preparing my study. Special thanks to
Engineer Tawfik A. Tawfik, Teacher assistant, Suez Canal University, Engineer Kimberly M.
Bounds, Executive Manager, TESCO Corporation North America Business Unite.
Also all the Managers and Engineers in Petrobel Company who gives me time to talk with
them about the different drilling data that needed to complete my study, especially Engineer
Sami Sisostris, Oil Reservoir Assistant General Manager.
11
NOMENCLATURE
BHA =Bottom Hole Assembly.
CDS = Casing Drive System.
CSG = Casing.
CwD = Casing while Drilling.
DCwD = Direction Casing While Drilling.
DLA = Drill Lock Assembly.
DLS = Dogleg Severity.
ECD = Equivalent Circulation Density.
EMW = Equivalent Mud Density.
EOB = End of Build
EOD = End of Drop
FIT = Formation integrity Test.
LCM = Loss of Circulation Material.
LGS = Low Gravity Solids.
LOT = Leak Off Test.
LWD = Logging While Drilling.
MD = Measured Depth.
MWD =Measurement While Drilling.
NPT = Non-Productive Time.
OBM = Oil Base Mud.
PLC = Programmable Logic Control.
PT = Production Time.
RKB = Rotary Kelly Bushing.
ROP = Rate of Penetration.
TVD = True Vertical Depth.
WBM = Water Base Mud.
REFERENCES
1- M. Kardos, The American Oil & Gas Reporter, April 2008. Drilling with casing Gains
Industry Acceptance.
2- Sections drilled statistic done by Tesco Corp. sent to me by TESCO Corp
3- Avery, Stephens, Al-Hadad and Turki, Abed, High Angle Directional Drilling with 9-in.
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